Reinforced pallet

ABSTRACT

A pallet assembly includes an upper deck having an upper panel portion from which a plurality of ribs extend downward. A plurality of channels are formed in an underside of the upper deck. The pallet assembly includes a plurality of columns below the upper deck. A plurality of reinforcement assemblies, including an inner reinforcement member, are each received within an outer case. The inner reinforcement members are received in the channels in the upper deck.

This application is a continuation of application Ser. No. 13/529,096, filed Jun. 21, 2012, which claims priority to U.S. Provisional Application No. 61/499,679, filed Jun. 21, 2011.

BACKGROUND

Some applications for plastic pallets require reinforcement members in order to achieve sufficient stiffness, such as for racking. In some of these applications, such as some applications involving food handling, it is desirable that the reinforcement members not be exposed, especially if they are metal. In other applications, the additional stiffness from the reinforcement members is unnecessary and would add unnecessary weight and cost.

If a pallet is designed to accommodate steel reinforcement, the upper deck will have channels formed therein for receiving the reinforcement members. Therefore, if one were to provide this pallet in a non-reinforced configuration, the empty channels would weaken the pallet. In order to avoid this, complicated inserts or other reconfigurable mold modifications would have to be provided in order to selectively close the channels to produce acceptable non-reinforced pallets from the same mold.

For food handling applications or other applications where exposed metal reinforcement members is undesirable, the reinforcement members may be contained within a two-piece deck. This increase in the cost and weight of the pallet is unnecessary if the reinforced pallet were to be provided for another application where exposure of the reinforcement members is not an issue.

SUMMARY

A pallet according to one example of the present invention provides the ability to be configured in several variations without any changes to the mold or to the upper deck or lower portion.

In the example described below, the pallet can be configured as a heavy duty reinforced pallet or as a medium or lighter duty pallet. The pallet can also be configured such that any metal reinforcement is not exposed.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a pallet according to one embodiment of the present invention.

FIG. 2 is a bottom perspective view of the pallet of FIG. 1.

FIG. 3 is an exploded view of the pallet of FIG. 1.

FIG. 4 is an exploded view of the pallet of FIG. 1 with an optional configuration of the reinforcement assemblies.

FIG. 5 is an exploded view of the reinforcement assemblies of FIG. 3.

FIG. 6 is an exploded view of one of the reinforcement assemblies of FIG. 5.

FIG. 7 is a section view of one of an inner reinforcement member with an optional cap secured thereto.

FIG. 8 is a bottom perspective view of the upper deck of FIG. 1.

FIG. 9 is a top view of the pallet of FIG. 1.

FIG. 10 is an end view of the pallet of FIG. 1.

FIG. 11 is a side view of the pallet of FIG. 1.

FIG. 12 is a partially exploded perspective view of the pallet of FIG. 1 in an optional configuration with just the reinforcement members, but without the outer cases.

FIG. 13 is an enlarged perspective view of the top of one of the columns of FIG. 12.

FIG. 14 shows an optional configuration of the pallet assembly of FIG. 12 with some outer cases used to fill in open channels.

FIG. 15 is a partially exploded view of the pallet in another optional configuration with just the plastic outer cases, but without the reinforcement members.

FIG. 16 is an enlarged view of the top of one of one of the columns of FIG. 15.

FIG. 17 shows another alternative reinforcement assembly that could be used in the pallet of FIG. 1.

FIG. 18 is a perspective view of a pallet according to a second embodiment of the present invention.

FIG. 19 is a bottom perspective view of the pallet of FIG. 18.

FIG. 20 is an exploded perspective view of the pallet of FIG. 18.

FIG. 21 is a perspective view of the lower portion of FIG. 18.

FIG. 22 is a second perspective view of the lower portion of FIG. 18.

FIG. 23 is a bottom perspective view of the upper deck.

FIG. 24 is a top view of the lower portion.

FIG. 25 is an end view of the lower portion.

FIG. 26 is a side view of the lower portion.

FIG. 27 illustrates one example mold assembly that could be used to form the lower portion of FIG. 21.

DESCRIPTION OF PREFERRED EMBODIMENTS

A pallet 10 according to a first embodiment of the present invention is shown in FIGS. 1-17. The pallet 10 includes an upper deck 12 and a lower portion 14. The lower portion 14 includes columns 16. The lower portion 14 may also include runners 18 connecting the columns 16. FIG. 2 is a bottom perspective view of the pallet 10. The upper deck 12 and the lower portion 14 in this example are each integrally molded as a single piece of plastic, but other configurations could be used.

FIG. 3 is an exploded view of the pallet 10. The pallet 10 includes a plurality of reinforcement assemblies 20. The reinforcement assemblies 20 provide increased strength and/or stiffness to the pallet 10. The reinforcement assemblies 20 may be between the upper deck 12 and columns 16 and received in channels 21 formed at upper ends of the columns 16. As shown in FIG. 3, the reinforcement assemblies 20 may be arranged three in the short dimension and two along the long dimension of the pallet 10. As shown in FIG. 4, the pallet 10 also permits the reinforcement assemblies 20 to be arranged as three in the long dimension and two along the short dimension of the pallet. This permits flexibility in choosing which dimension requires more stiffness.

As shown in FIGS. 5 and 6, the reinforcement assemblies 20 each have an inner reinforcement member 22 and an outer case 24. The reinforcement member 22 may be steel or some other metal. Alternatively, the reinforcement member 22 may be a composite plastic or a more expensive, stiffer or stronger polymer or composite (compared to the material of the upper deck 12 and/or lower portion 14). The outer case 24 may be extruded plastic segments, such as polyethylene, into which the reinforcement members 22 are inserted. The outer case 24 may be selected to match the material of the upper deck 12 and/or lower portion 14. Optionally, plastic caps 26 may be connected to ends of the reinforcement members 22, as shown in FIG. 7. In this manner, the outer surfaces of the reinforcement members 22 are not exposed. This provides a more uniform appearance to the pallet 10 and may impede any potential corrosion of the reinforcement members 22. Alternatively, or additionally, the reinforcement members 22 may be coated with a polymer, such as plastisol (or similar), which cures in place on the reinforcement members 22.

FIG. 8 is a bottom perspective view of the upper deck 12. The upper deck 12 includes a planar upper panel portion 28 from which a plurality of ribs 30 extend downward. Channels 32 are formed in the ribs 30 to accommodate the reinforcement assemblies 20. The channels 32 accommodate either arrangement of reinforcements (FIG. 3 or FIG. 4). Some of the ribs form upper column portions 34, which mate with the columns 16 of the lower portion 14. FIG. 9 is a top view of the pallet 10. FIG. 10 is an end view of the pallet 10. FIG. 11 is a side view of the pallet 10.

FIGS. 12 and 13 show the pallet 10 in an optional configuration with just the reinforcement members 22, but without the outer cases 24. This could be used for applications where heavy reinforcement is required, but exposed reinforcement members 22 (especially if they are steel) are acceptable. Without the outer cases 24, larger reinforcement members 22 could be used for the same size channels 21, 32 in the lower portion 14 and upper deck 12.

As shown in FIG. 14, the remaining portions of the channels in the deck 12 and lower portion 14 not occupied by the reinforcement members 22 can be filled with short sections of outer cases 24 to eliminate any potential weaknesses in the pallet 10 from the open channels. This provides optional configurations of the pallet 10, with different stiffness, cost and weight, without the need for reconfiguration of the mold (such as with mold inserts) to close up the channels 21, 32 in the lower portion 14 and upper deck 12, while still avoiding any weaknesses created by the channels 21, 32.

FIGS. 15 and 16 show the pallet 10 in another optional configuration with just the plastic outer cases 24, but without the reinforcement members 22. This is a lighter, lower cost, medium duty configuration of the pallet 10. The plastic of the outer cases 24 could be the same plastic as the deck 12 and/or lower portion 14, or the plastic of the outer cases 24 could be a stiffer material than that of the deck 12 and/or lower portion 14 to increase the stiffness of the pallet 10 moderately. The outer cases 24 could be extruded with wall thickness suitable for the application of the pallet 10 to provide the appropriate stiffness, weight and cost balance.

FIG. 17 shows another alternative reinforcement assembly 20 a. In FIG. 17, the outer case 24 a is U-shaped and fits over the reinforcement member 22, enclosing the reinforcement member 22 on the bottom and sides, while the upper panel portion 28 (FIG. 8) of the deck 12 covers the reinforcement member 22 on the top.

It should also be noted that the reinforcement elements (e.g. reinforcement assembly 20, reinforcement member 22, outer case 24 and outer case 24 a) can be used in different combinations in the same pallet 10. For example, a given application may only require reinforcement members 22 or covered reinforcement assemblies 20 or 20 a along the long dimension of the pallet 10 and only the outer cases 24 along the short dimension of the pallet 10 (or vice versa). As another example, it may be determined that only one reinforcement member 22 is required, while the rest can be the outer cases 24.

In this manner, the same deck 12 and lower portion 14 can be used with different arrangements of reinforcement elements to provide these different configurations for different applications. This is accomplished without modifications to the molds or removable inserts for the molds for the deck 12 or lower portion 14.

FIGS. 18-27 show a pallet 110 according to a second embodiment of the present invention. The pallet 110 includes an upper deck 112 and a lower portion 114. The lower portion 114 includes columns 116. The lower portion 114 may also include runners 118 connecting the columns 116. FIG. 19 is a bottom perspective view of the pallet 110. The upper deck 112 and the lower portion 114 in this example are each integrally molded as a single piece of plastic, but other configurations could be utilized.

FIG. 20 is an exploded view of the pallet 110. The pallet 110 includes a plurality of reinforcement members 122. The reinforcement members 122 provide increased strength and/or stiffness to the pallet 110. The lower portion 114 includes a plurality of channels 140 extending between upper end portions of adjacent columns 116. The channels 140 are molded integrally with the columns 116 and accommodate the reinforcement members 122. FIGS. 21 and 22 are perspective views of the lower portion 114. The channels 140 each include a bottom wall and two spaced apart side walls. The reinforcement members 122 can be at least partially accommodated in the channels 140.

FIG. 23 is a bottom perspective view of the upper deck 112. The upper deck 112 includes a planar upper panel portion 128 from which a plurality of ribs 130 extend downward. Channels 132 are formed in the ribs 130 to accommodate the reinforcement members 122. Some of the ribs form upper column portions 134, which mate with the columns 116 of the lower portion 114. FIG. 24 is a top view of the lower portion 114. FIG. 25 is an end view of the lower portion 114. FIG. 26 is a side view of the lower portion 114.

With either embodiment, the reinforcement members 22, 122 are hidden and protected. The reinforcement members 22, 122 are shown as having a square cross section, but other shapes, such as I-beam could also be used.

FIG. 27 illustrates one example mold assembly 200 that could be used to form the pallet 110. The mold assembly 200 includes an upper mold half 202, a lower mold half 204 and a plurality of lateral slides 206 that form the channels 140 (FIG. 14).

In all of the embodiments above, the channels 21, 32, 132 could be a standard size such as ¾″×¾″ or 1″×1″ or 1¼″×1¼″ or a rectangular standard.

In accordance with the provisions of the patent statutes and jurisprudence, exemplary configurations described above are considered to represent a preferred embodiment of the invention. However, it should be noted that the invention can be practiced otherwise than as specifically illustrated and described without departing from its spirit or scope. 

What is claimed is:
 1. A pallet assembly comprising: an upper deck having an upper panel portion from which a plurality of ribs extend downward, a plurality of channels formed in an underside of the upper deck; a plurality of columns below the upper deck; a plurality of reinforcement assemblies each including an inner reinforcement members each received within a first outer case, the inner reinforcement assemblies received in the plurality of channels, a plurality of second outer cases received in the channels, the second cases not containing inner reinforcement members therein.
 2. The pallet assembly of claim 1, wherein the first outer cases are integrally molded with the columns.
 3. The pallet assembly of claim 1, wherein the plurality of reinforcement assemblies are receivable in the plurality of channels in a first orientation and are receivable in the plurality of channels in a second orientation perpendicular to the first orientation.
 4. The pallet assembly of claim 1, further including end caps covering longitudinal ends of the plurality of inner reinforcement members.
 5. The pallet assembly of claim 1, wherein the plurality of inner reinforcement members each have a hollow rectangular cross section.
 6. The pallet assembly of claim 1, wherein the first outer cases are configured such that they can be received in the channels without the inner reinforcement members.
 7. The pallet assembly of claim 1, wherein the first and second outer cases are plastic and the inner reinforcement members are metal.
 8. The pallet assembly of claim 7, wherein the first outer cases are configured such that they can be received in the channels without the inner reinforcement members.
 9. The pallet assembly of claim 8, wherein the plurality of reinforcement assemblies are receivable in the plurality of channels in a first orientation and are receivable in the plurality of channels in a second orientation perpendicular to the first orientation.
 10. The pallet assembly of claim 9, further including end caps covering longitudinal ends of the plurality of inner reinforcement members.
 11. The pallet assembly of claim 10, wherein the inner reinforcement members have a hollow rectangular cross section.
 12. The pallet assembly of claim 11 wherein the plurality of columns each include at least one channel formed at an upper end thereof, the plurality of reinforcement assemblies and the second outer cases received in the channels at the upper ends of the plurality of columns.
 13. The pallet assembly of claim 1 wherein the plurality of columns each include at least one channel formed at an upper end thereof, the plurality of reinforcement assemblies and the second outer cases received in the channels at the upper ends of the plurality of columns.
 14. A pallet assembly comprising: an upper deck having an upper panel portion from which a plurality of ribs extend downward, a plurality of channels formed in an underside of the upper deck; a plurality of columns below the upper deck; and a plurality of reinforcement assemblies including a plurality of inner reinforcement members each received within a first outer case, the inner reinforcement members received in the plurality of channels, wherein the outer case has a three-sided cross-section with an open side, such that the outer case has a U-shaped cross section, wherein the upper panel portion covers the inner reinforcement members on the open side of the outer case.
 15. A pallet assembly comprising: an upper deck having an upper panel portion from which a plurality of ribs extend downward, a plurality of channels formed in an underside of the upper deck; a plurality of columns below the upper deck; a plurality of plastic outer cases having a hollow rectangular cross section, the plastic outer cases received in the plurality of channels; and a plurality of inner reinforcement members received within some, but not all, of the plurality of outer cases.
 16. The pallet assembly of claim 15, wherein the inner reinforcement members are metal.
 17. The pallet assembly of claim 16, further including end caps covering longitudinal ends of the outer cases.
 18. The pallet assembly of claim 15, wherein the plurality of outer cases are receivable in the plurality of channels in a first orientation and are receivable in the plurality of channels in a second orientation perpendicular to the first orientation.
 19. The pallet assembly of claim 18 wherein the plurality of columns each include at least one channel formed at an upper end thereof, the plurality of inner reinforcement members and the plurality of plastic outer cases received in the channels at the upper ends of the plurality of columns. 